CN101071673A

CN101071673A - Gapped core structure for magnetic components

Info

Publication number: CN101071673A
Application number: CNA2007100923577A
Authority: CN
Inventors: R·L·汉利
Original assignee: Cooper Technologies Co
Current assignee: Eaton Intelligent Power Ltd
Priority date: 2006-02-15
Filing date: 2007-02-14
Publication date: 2007-11-14
Anticipated expiration: 2027-02-14
Also published as: JP2007227914A; TW200741765A; CN101071673B; KR20070082539A; TWI357608B

Abstract

A single piece core structure for magnetic components that is formed without utilizing insulating spacer materials and bonding materials is disclosed. The magnetic component comprise a single core construction, a rectangle main body made of magneto- material defined by opposing end-face, opposing side extended between terminal ends and connected top side, bottom side, side and terminal side. The first conductor open pore separated with each end-face, top side and bottom side extends and thrills through the main body. A first gap formed entirely in the main body and course extended to conductor open pore, and the gap extensibility is not exclusively thrill through the main body. And first conductor element thrilling first conductor open pore and forming a electric conduction alley way is configured as a surface mounting end.

Description

The interstitial iron core structure of magnetic cell

The cross reference of related application

The application is US10/736, the further part of 059 patent application, and require at first to file US60/435,414 right, the applying date is on December 19th, 2002, its disclosed content is incorporated herein by reference.

Technical field

The application relates generally to the manufacturing of electronic component, particularly magnetic cell, for example manufacturing of inductor.

Background technology

Various magnetic cells include but not limited to inductor and transformer, have at least one coil arrangement and become around field core.In some elements, assembly unshakable in one's determination is made of the ferrite core that also bonds at interval.In use, the gap between the iron core requires storage power in iron core, and the magnetic characteristic that causes in gap, includes but not limited to open inductance and direct current offset characteristic.In micro element, the manufacturing in the uniform gap between the iron core is significant for reliable, high-quality production magnetic cell especially.

For example, epoxy material is used to the bonded ferrite magnetic core to produce the bonding magnetic core assembly of magnetic cell.For the consistency of interferric space, nonmagnetic little ball, particularly glass marble are mixed in insulating adhesive material sometimes, and are distributed in and form the gap between the iron core.During heating, the epoxy material bonding is unshakable in one's determination, and little ball is separately unshakable in one's determination to form the gap simultaneously.Bonding, still mainly rely on epoxy material bonding and unshakable in one's determination between the ratio of epoxy material and little ball in the bonding intermixture that distributes.Notice, in some applications, since special, can not use bonding unshakable in one's determination, and the proportional control of binder mixture epoxy material and glass marble also is very difficult.

In the magnetic cell of other types, the interval insulant of non-magnetic is used between two magnetic half-cores, and two half-cores compress the maintenance interval insulant mutually.Interval insulant uses paper or polyester insulated material usually.Especially, half-core and interval reliably interfix with the band that is wound onto outside the half-core, and adhesive guarantees fixing between the half-core, and perhaps, anchor clamps guarantee the gap between fixing of half-core and the maintenance half-core.In the time of indivedual, use many (more than 2) sheet interval insulant, this is to become complicated, difficult and expensive owing to guarantee the integral body of structure.

The magnetic cell of other types arrives the part of half-core at the bottom of comprising a gap, and keeps the part of half-core to adopt aforesaid any technology to compress other half-core.

At present, the additive method that produces the gap in core construction is to make the monolithic iron core earlier, downcuts sheeting from (being typically ring-shaped core) unshakable in one's determination.The gap is filled to keep intensity and shape unshakable in one's determination by adhesive or epoxy material usually.

Recently, the synthesizing magnetic ceramic ring comprises that the layered magnetic structure that separates to form the gap with non-magnetosphere is developed.For example, referring to patent US6,162,311.Therefore, can save the outer gap material (for example, at interval) of binding material (for example, adhesive) and core const ruction.

In any aforesaid device, conductor is placed to pass iron core usually, and with the form coupling energy of magnetic flux, the magnetic line of force passes and around the gap, forms magnetic circuit in iron core.If conductor inserts magnetic flux line, have circulation in the conductor.Because circulation, the resistance in the conductor produces heat, and this has reduced the efficient of magnetic cell.Conductor can reduce the energy that is coupled to conductor away from moving of magnetic flux line, therefore can improve the efficient of element, but this can cause the increase of component size, and this is undesirable on making.

Simultaneously, existing magnetic cell is assembled into the single-core structure usually.For example, when using a plurality of inductor, unshakable in one's determination must physical separation to prevent phase mutual interference in the work.The separation of element has taken the useful space on the printed circuit board (PCB).

Therefore, be desirable to provide a kind of magnetic cell, can raise the efficiency and improve manufacturability and be used for circuit board, and do not need the space that increases size of component or take printed circuit board (PCB).

Description of drawings

Fig. 1 is the perspective view that is used to make the exemplary interstitial iron core structure of magnetic cell.

Fig. 2 is the end view that is equipped with the iron core of inductor shown in Fig. 1.

Fig. 3 is core construction shown in Fig. 2 and inductor cutaway view.

Fig. 4 is the partial sectional view of Fig. 3, has shown the magnetic line of force of core construction.

Fig. 5 is second embodiment of interstitial iron core structure.

Fig. 6 is the 3rd embodiment of interstitial iron core structure.

Fig. 7 is the end view of the 4th embodiment of interstitial iron core structure.

Fig. 8 is the bottom view of iron core shown in Figure 7.

Fig. 9 is the cutaway view of core construction shown in Figure 8.

Figure 10 is the end view of the core construction that inductor is set therein shown in Figure 7.

Figure 11 is the bottom view of structure shown in Figure 10.

Figure 12 is the end view of core construction shown in Figure 11.

Figure 13 is the end view of interstitial iron core structure the 5th embodiment.

Figure 14 is the bottom view of iron core shown in Figure 13.

Figure 15 is the cutaway view of the iron core that shows of Figure 14.

Figure 16 is that iron shown in Figure 13 wherein is provided with the end view that the core structure of inductor comprises.

Figure 17 is the bottom view of structure shown in Figure 16.

Figure 18 is a core construction end view shown in Figure 17.

Embodiment

Fig. 1 is the perspective view of the exemplary gap magnetic core structure 10 of magnetic cell, and magnetic cell can be that for example inductor, transformer and other comprise the magnetic cell of interstitial iron core structure.Core construction 10 comprises a plurality of magnetospheres 12 of stacked structure that are, wherein non-magnetosphere 14 extends between two magnetospheres 12 and it is separated, and interrupts passing the magnetic circuit of core construction 10 to form whole gap.

As shown in Figure 1, core construction 10 is used to form single magnetic cell, for example, and inductor.Core construction 10 is by layer magnetosphere 12 that forms of the magnetic ceramics material of be untreated (quenching), and a layer formation non-magnetosphere 14 merging of untreated nonmagnetic ceramic core material constitute.The magnetic ceramics material is as iron core, and nonmagnetic ceramic materials is as the gap simultaneously.

The part of the ceramic material of the layering of core construction 10 is removed the zone or the perforate 16 (not showing among Fig. 1) of passing conductor element with generation.In exemplary embodiment, perforate 16 be basically rectangle and limit by the outside 15 of magnetosphere 12 and the outside 18 of non-magnetosphere 14.Side 17 is extended from the limit 15 of magnetosphere 12 and end face 19 extends the endoporus that passes core construction 10 with formation from the limit 18 of non-magnetosphere 14.In another embodiment, perforate 16 and/or hole can be manufactured into other shape, rather than rectangle shown in Figure 3.

In case magnetosphere 12 and non-magnetosphere 14 are stacked into suitable thickness and bond together, for example known laminate patch is handled, and perforate 16 forms according to technique known, and for example punching press is handled.Core construction 10 is then quenched obtains the characteristic of net shape and core construction.Therefore gap magnetic core 10 is made into overall structure.Gap size is controlled in the overall dimension of mass production, with the mutual inductance value that obtains reliably controlling.

The overall structure of magnetic core 10 has many good qualities on making.For example, reduced bonding external series gap material, and relevant expense and difficulty, therefore overall structure can not separate.Whole interstitial structure can be controlled the mutual inductance value reliably, and conductor material flux loss and the thermal losses in use in the iron core can be reduced in a plurality of little gap (having replaced one or two big gap on the conventional iron core structure).And the introducing in gap does not need mechanism.As a result, the magnetic cell that comprises core construction 10 can keep the firm of gap length degree and reliable control.

Ferrite Material can be used as magnetic media and forms 10 magnetospheres 12 unshakable in one's determination on a large scale.Exemplary Ferrite Material comprises manganese-zinc ferrite, and power ferrite particularly, nickel-zinc ferrite, lithium-zinc-ferrite, MgZn ferrite or similarly can be used as commercial the application, and use widely.For non-magnetosphere 14, on a large scale ceramic material can use, and comprises for example aluminium oxide, alumina glass mixture, cordierite, cordierite glass mixture, mullite, mullite glass mixture, zirconia, zirconia glass mixture, ba titanate and other titanates, steatite, ferrite mixture and non-magnetic pottery and the similar non-magnetic or the weak magnetic ceramic material that can quench with Ferrite Material.Can revise sintering temperature and the contraction of quenching to the interpolation of glassy phase in the non-magnetic pottery.This is very important for the thermal characteristics that must mate the magnetic phase as non-magnetic material, for example, and ferrite.Can not well mate if the quenching of two kinds of materials is shunk, element can not move on request.

The embodiment that Fig. 1 shows comprises three magnetospheres 12 and a non-magnetosphere 14, can estimate can use in the alternate embodiments that does not deviate from scope of the present invention more or less magnetosphere 12 or non-magnetosphere more or less 14.Further,, be appreciated that, can use the core construction of other shapes, comprise and not limiting to and the known annular shape of prior art mentioning among the embodiment though the core construction 10 that Fig. 1 shows is rectangular configuration basically.

Be applied in 10 magnetic characteristics of the thickness effect core const ruction of the ferritic type of magnetosphere 12 and non-magnetosphere 14, and the characteristic that finally influences the magnetic cell at its place.Power dissipation density, for example, can difference supposes that wherein the switching voltage regulating element is particularly conducive to the minimizing power loss by changing ferritic position.Osmotic effect, the characteristic that another one is important is controlled by the largest portion of non-magnetosphere 14 thickness.

Fig. 2 is the end view that the core construction 10 of inductor component 20 is installed.In the exemplary embodiment, the known conductor material of conductor element 20 usefulness is made, and it is terminal accordingly passing conductor perforate 16 (Fig. 1) formation or bending.In the exemplary embodiment of Fig. 2, core construction 10 and conductor element 20 are fit to form inductor very much.The assembly of core construction 10 and conductor element 20 is assembling automatically on demand easily.A plurality of conductor elements 20 can be inserted in the core construction 10 as single bootstrapping architecture, then are formed or are adjusted into final products.Therefore a large amount of magnetic cells can be with relatively, for example known inductor, lower price manufacturing.

Fig. 3 is the cutaway view of core construction 10 and conductor element 20, has shown that conductor element 20 contacts and is supported by it with non-magnetosphere 14, and placed in the middle substantially with respect to conductor perforate 16 in addition.That is to say that conductor element 20 is in abutting connection with the end face 19 of non-magnetosphere 14, but and the side 15 of the magnetic material 12 in the perforate 16 about equally distance apart.Equally, the inner surface 17 of non-the magnetic gap following and conductor element 20 that always extends to conductor element 20 and perforate 16 separately.

Shown in the exemplary embodiment of Fig. 3, conductor element 20 shapes and conductor perforate 16 complementations, and the cross section of the two is rectangle substantially in this embodiment.But, be appreciated that the cross section of other shapes of conductor element 20 and conductor perforate 16 also can be used for alternate embodiments of the present invention, reach one of beneficial effect of the present invention simultaneously at least.Among another embodiment, notice that conductor 20 and conductor perforate 16 do not need complementation can realize direct beneficial effect of the present invention yet.

Further, when conductor element shown in Figure 2 20 is inserted in the core construction 10, can predict, core construction 10 lip-deep conductor materials can be replaced, perhaps, interchangeable, can utilize the known conductor ink that for example is used for thick-film technique, electric conducting material is printed on the core construction 10.

Fig. 4 schematically shows core construction 10 magnetic line of force in use, and special, notices that conductor element 20 does not enter the magnetic line of force.Like this, the induced current in the conductor element 20 has reduced, and has avoided relevant thermal losses, and the efficient of magnetic cell has improved.The efficiency of element that increases can obtain in a simple elements size.

Those skilled in the art as can be known, efficiency of element depends on high switching frequency most.Said structure has single turn conductor element 20, is particularly suitable for the application of high frequency.But can think that the conductor element that similarly has multiturn also can be used for alternate embodiments of the present invention.

Fig. 5 is second embodiment of interstitial iron core structure 30, has shown the compound clearance core construction.The

layer

12,14 of aforesaid magnetic and non-magnetic material is stacked into single structure and can produces compound magnetic cell, as mentioned above, and on single or integral core structure 30.Like this, two, three or more magnetic cell are such as inductor, for example can be configured to a core construction 30, as shown in Figure 5, when leading an element, be placed in such as conductor element 20 (shown in Fig. 2 and 3) and pass perforate 16, or be formed on unshakable in one's determination 30 surface in addition when conducting element.

Utilization is used for the synthetic core construction 30 of integral body of compound magnetic cell, because the cost of encapsulation and carrying first is lower than a plurality of parts of carrying, so cost can reduce.Whole system cost also can reduce, owing to arrange that less components has reduced cost.Also have another advantage to be, core construction 30 has used less board area with respect to magnetic cell (the single inductor shown in Fig. 2,3) independently.Compound inductors is integrated into single-core structure 30 with respect to element independently with unshakable in one's determinationly taken less space, because the necessary physical clearance of independent component does not need in integrated core construction 30.

As shown in Figure 5, core construction 30 is made by a series of magnetospheres 12 that pile up, and it is separated by at least one non-magnetosphere 14.Magnetosphere 12 horizontal-extendings and by vertical stacking, a plurality of conductor perforates 16 are formed on the magnetic and non-magnetosphere 12,14 that piles up.Conductor perforate 16 by vertical non-magnetosphere or insulating barrier 32 separately, and vertically extending insulating barrier 32 is bonded to the magnetic and the non-magnetosphere 12,14 of vertical stacking, and conductor perforate 16 is wherein arranged.Like this, core construction 30 can think that a plurality of core constructions 10 (shown in Fig. 1-4) connect together with the structure of side to the side, to form big core construction 30.Vertically extending insulating barrier 32 can be bonded between the

stack layer

12,14 before perforate 16 forms, and core construction 30 is quenched as single structure formation net shape.

In case finish, the conductor perforate 16 of conductor element is installed, for example above-mentioned inductor component 20 forms a plurality of magnetic cells from same singlecore structure.The result is like this than using independent component, inductor for example, and whole cost reduces, especially in the time of use Automation Elements assembly equipment.Merging sensor structure on unshakable in one's determination 30 is littler than a plurality of independently inductors occupation space on circuit, owing to do not need physical separation or " remaining on outer " zone.In addition, be used for the application of the single magnetic core structure 30 of many conductor elements, allow influence value to follow mutually and since the warming-up effect of independent inductor similar other inductors on the same structure.

Core construction 30 is specially adapted to composite voltage adjustment module (VRM), and it is usually used in the application of high-performance, big electric current.The whole electric current of VRM load be each VRM cross section and.Because a plurality of inductors can be used for voltage regulator circuit, it has and merges the advantage of more inductor in the single encapsulation of core construction 30.

When the

stack layer

12,14 when unshakable in one's determination 30 comprises four magnetospheres 12 and a non-magnetosphere 14, can think also can be used for more or less magnetosphere 12 and not exceed scope of the present invention more than one non-magnetosphere 14.Select a step, as mentioned above, for unshakable in one's determination 10, core construction 30 is unnecessary to be rectangle, also unnecessary conductor perforate with rectangle realizes direct beneficial effect of the present invention, therefore in different embodiment, for most of core construction 30 operable difformities and/or conductor perforate 16.

Fig. 6 is the 3rd embodiment, has shown core construction 50, and wherein a plurality of core constructions are stacked on the nonmagnetic insulating layer 52 of adjacency, and by its separation.In this example embodiment, each core construction comprises two non-magnetosphere 14 therebetween between magnetosphere 12, and insulating barrier 52 extend between each core construction and be basically parallel to each core construction the layer 12,14.Non-magnetosphere 14 is at the opposite side of conductor perforate 16.Insulating barrier 52 can be bonded in

stack layer

12,14 before or after perforate 16 forms, core construction 50 quenches and becomes net shape.

Though core construction 50

stack layers

12,14 comprise three magnetospheres 12 and two non-magnetospheres 14, can think and also can use more or less non-magnetosphere 14 or magnetosphere 12 and do not exceed scope of the present invention.Further, as mentioned above, for core construction 30, structure 50 does not need the whole rectangle that is, do not need to have rectangle opening yet and just can realize direct beneficial effect of the present invention, therefore, in different embodiment, for most of core construction 30 operable difformities and/or conductor perforate 16.

Although these embodiment have shown the structure that comprises three magnetic cells in an integral core structure, can think, more than or be less than three magnetic cells or circuit and also can be merged into a single structure and be used for further and/or alternate embodiments.

Though different on the structure, core construction 50 can provide and the essentially identical beneficial effect of core construction 30 (shown in Figure 5).

Provide a kind of interstitial iron core structure that is used to make magnetic cell, such as inductor, transformer or other elements.The bonding and the outer gap material that are used for the conventional iron core structure have been omitted, reduce the edge flux loss of conductor material by using compound little gap (having substituted one or two bigger gap), with the raising electrical efficiency, and this mechanism allows the value of control mutual inductance reliably.The setting in gap makes edge flux leave conductor, makes maximizing efficiency, and compound inductors can be assembled in the single-core structure, has reduced whole costs and size.

Fig. 7-9 has shown another embodiment of interstitial iron core structure 100, and it is used for magnetic cell such as inductor, transformer and other magnetic cells, comprises the interstitial iron core structure, also can provide as above-mentioned structure 30 and 50 similar beneficial effects.Be similar to structure 30 and 50, interstitial iron core structure 100 avoided on the whole typically being used for circuit board surface installation elements conventional magnetic element the outer gap material be connected binding material and adhesive.Therefore the reliability problems that a plurality of laminations of having avoided bonding together separate, its influence tradition bonding core construction.In addition, the relative conventional iron core structure of the manufacturing of core construction 100 has been simplified, and has realized in the saving of assemblage gap core construction 100 to the circuit board time space.

Fig. 7 is the end view of interstitial iron core structure 100, and Fig. 8 and 9 is respectively the bottom view and the cutaway view of interstitial iron core structure 100.Referring now to Fig. 7-9, core construction 100 comprises the basic body 102 of rectangle that is, it has

opposing end faces

104 and 106, opposed

side edges

107 and 108 is extended between

end face

104 and 106, and end face 110 and bottom surface 112

end face

104 and 106 and

side

107 and 108 between extend and connect.Body 102 can be elongated and be limited by the longitudinal axis 114 and transverse axis 116.As shown in the figure,

side

107 and 108, and end face 110 and bottom surface 112 are parallel to the longitudinal axis 114 and extend, and

end face

104 and 106 substantially parallel transverse axis 116.Though body 102 example of shape are rectangle, are appreciated that the shape that also can use alternative body 102 in other embodiments if desired.

Body 102 can form monolithic and by known magnetizing mediums or made, comprise above-mentioned in exemplary embodiment Ferrite Material arbitrarily.Known technology or technology can be used to make body 102.Especially, different with 50 with above-mentioned core construction 30, core construction 100 is not included in the non-magnetic material in the structure of core construction 100, such as above-mentioned non-magnetosphere 14 and 32.That is to say, replacement about iron core structure 30 with 50 form monolithic in above-mentioned mode by different materials, the body 102 of core construction is made by same magnetic material, and the sheet or the section that do not need to insert non-magnetic or insulating material are passed body 102 to the single integrated piece with uncertain relatively magnetic characteristic.In addition, in an exemplary embodiment, body 102 is made of the magnetic material fully, be different from synthetic material, so-called distributed air gaps core material has, and for example iron powder and resin binder mix mutually with microsize grade, so the generation of channel effect does not form the discontinuous interstice in structure.But in other embodiments, if desired, can use synthetic material.

Conductor perforate 118,120 (Fig. 7) can be formed in the body 102, and perforate 118,120 can integral body extend through body 102 between

side

107 and 108, as Fig. 9.Each perforate 118,120 is by side 107 and opened in 108 minutes and therebetween, and between end face on

side

107 and 108 110 and bottom surface 112.Each conductor perforate 118,120 quadrature or extend perpendicular to side 107,108, and and the outer rim of

side

107 and 108 arrange at interval, in exemplary embodiment, limited by end face 110 and bottom surface 112 and side 107,108.Just, conductor perforate 118,120 each be positioned at the centre position of the outer rim of

side

107 and 108.

Conductor perforate 118 and 120 can be, rectangle opening for example, and is parallel to the longitudinal axis 114, although also can use the perforate of other shapes in other embodiment.Perforate 118,120 can be integrated in the body 102 according to known method, mold and/or the machining used always including, but not limited to those skilled in the art.Though two perforates 118,120 shown in the embodiment of Fig. 7-9 in alternative embodiment, can have more or less perforate 118,120.

Discontinuous non-magnetic gap 122,124 also can be integrated in the body 102, and each gap 112,124 is relevant with a conductor perforate 118,120.Gap 122,124 physically is formed in the body 102, for example, and by known mold and/or machining.Especially, form gap 122,124 o'clock at any way, all without outer gap material and relevant binding material and adhesive, and need not any packing material outside 122,124 deacration of gap.That is to say that in exemplary embodiment, the formation in gap 122,124 refers to the outer gap material sometimes without any need for insulating material, is applied in the body.But, be appreciated that in alternative embodiment non-magnetic material also can preferably be used in gap 122,124, still can realize beneficial effect of the present invention.

In the embodiment of example, as shown in Figure 7, gap 122,124 extends transverse to corresponding conductor perforate 118,120.For example, each gap 122,124 has corresponding end 126,128.End 126 terminates in corresponding conductor perforate 118,120 and opens to the conductor perforate 118,120 of correspondence, therefore, arranges fixing and not corresponding perforate 118,120 contacts of end 126 in gap 122,124.The outer rim that the opposite end 128 in each gap 122,124 extends to side 107,108 more particularly arrives bottom surface 112.Conductor perforate 122,124 is divided in each gap 122,124 substantially equally and the quadrature extension is hung down as for conductor perforate 122,124, therefore, sees gap 122,124 and conductor perforate the 118, the 120th, T shape shape from the side.

As shown in Figure 8, gap 122,124 extends to another side 108 with the direction of parallel transverse axis 116 from a side 107.That is to say that gap 122,124 is extended in the horizontal direction and passed completely through body 102 between side 107,108.But can be in vertical direction extend between a side end face 110 of conductor perforate 118,120 and bottom surface 112 in gap 122,124, and more particularly, in the exemplary embodiment of Fig. 7, it can extend between conductor perforate 118,120 and bottom surface 112.Especially, does not extend between the end face 110 of conductor perforate 118,120 and body 102 in gap 122,124.Like this, extend between the end face 120 of body 102 and bottom surface 112 fully in gap 122,124.The incomplete extension in gap 122,124 and the core construction with half-core form contrast, and with the clearance material bonding, clearance material extends between whole half-core half-core mutually.Rely on integral body 102, on a single-core structure 100, eliminated the multi-disc iron core, reduced the assembling difficulty simultaneously, and reduced discrete integrity problem unshakable in one's determination in the element use by integrated gap 122,124.With respect to the conventional iron core structure, single-core structure 100 has reduced material cost and accessory cost.

The bottom surface 112 of body 102 can form indentation or concave face 130, and it defines the zone of the conductor (following) that is assembled into core construction 100.

Figure 10-12 similar Fig. 7-9 inserts the conductor element 140 that passes core construction 100 but have, and more particularly, the conductor perforate 118,120 of passing body 102 is to form magnetic cell 138.Conductor element 140 in shape with conductor perforate 118,120 complementations, and can, for example rectangle and flat substantially ribbon conductor, it is made by known conductor material copper or copper alloy in one embodiment.Conductor element 140 straight-line extension basically passes corresponding conductor perforate 118,120, through the side 107 of body 102 and 108 whole distance, as shown in figure 12, and the opposite end 142 of each element 140 reel and abut to form depression 130 around

side

107 and 108 in the bottom surface 112 of body 102.Therefore the end 142 of conductor element 140 limits square surface and terminal contacts 144 is installed on the bottom surface 112 of body 102.When the conductive path of connecting circuit plate (not shown), terminal contacts 144 is finished the electrical connection by element.

Conducting element 140 can be according to known punching press, dash roll or forming technique by the flat board of conductor material with the manufacturing of guiding framework (not shown), the guiding framework can be used to simulate and inserts conductor element 140 and pass unshakable in one's determination 100 body 102.The guiding framework is followed end 142 bendings of balance conductor element 140 or conductor element 140 or otherwise is shaped to C shape, as shown in figure 12.Use automation process and machinery to finish in the set-up time that the assembling of conductor element 140 therefore can be minimum.

In case conductor element group 140 installs in unshakable in one's determination 100, each conductor element 140 and associated gap 122,124 can be used as independent inductor and move in single-core structure 100.In addition, each conductor element 140 can be connected to the different phase of electric current, therefore provides the two-phase magnetic cell in a single-core structure 100.Monolithic core construction 100 has been saved the space on the circuit board with respect to having independent core construction and independent inductor component.

The mounted on surface magnetic cell has monolithic interstitial iron core structure 100, therefore can realize above-mentioned unshakable in one's determination 30 and 50 similar beneficial effect.Core construction 100 can reduce manufacturing cost, and improves reliability, because monolithic iron core 100 has been eliminated the problem of separation unshakable in one's determination.

Figure 13-18 has shown the 5th embodiment of interstitial iron core structure 200 and magnetic cell 201, and the feature of wherein similar core construction 100 has similar characteristic.

Obviously, core construction 200 is similar to core construction 100, and has more conductor perforate, relevant gap and conductor element.That is to say that the body 202 of core construction 200 comprises except conductor perforate 118 and 120, also having four conductor perforates 204,206,208 and 210 in addition.Similarly, except gap 122,124, body 202 comprises that also discontinuous gap 212,214,216 and 218 mode and directions with similar substantially above-mentioned

gap

122 and 124 form.Pass the conductor perforate of body 202 and form C shape structure when conductor element 140 inserts, as shown in figure 18, conductor element 140 is integrated in the single-core structure 200 as six different mounted on surface inductor components with 218 with corresponding gap 122,124,212,214,216.Each conducting element 140 can be connected to the conductive path of circuit by the mounted on surface end, to six different phases of electric current, has saved the space of circuit board with exercisable connection conducting element.Core construction 200 also has the beneficial effect same with core construction 100.

Core construction 100 and 200 is particularly suitable for having multivoltage adjustment module (VRM) high frequency characteristics and big electric current.But, complementary, in other are used, also can obtain the beneficial effect of core construction 100 and 200, and the present invention is not limited in any specific application and the use.

An embodiment of magnetic cell described herein comprises that making basic by the magnetic material is the integral core structure of the body of rectangle.Body is limited by opposing end faces, and relative side extends between end face, end face and bottom surface and side and end face interconnection.The first conductor perforate and each end face, end face and interval, bottom surface, the open integral body of first conductor is passed body.First gap is integrally formed in body and extends transverse to the conductor perforate.The gap is prolonged and is not exclusively passed body, and first conductor element passes the first conductor perforate and set up conductive channel, and first conductor element is configured to the mounted on surface end.

Preferably, conductor element can comprise rectangular conductor.The second conductor perforate can be formed on the body and and the first conductor perforate at interval, second gap can be formed on the body and extend transverse to the second conductor perforate, and second conductor element can pass the second conductor perforate and sets up conductive path.First gap extends to the first conductor perforate and first gap and the first conductor perforate and is configured to T shape structure.Body can be limited by the longitudinal axis and transverse axis, and the first conductor perforate simultaneously and first gap are basically parallel to transverse axis extends, and usually mutual vertical extent between the first conductor perforate and first gap.The bottom surface comprises relative sunk surface, and first conductor element can be reeled around opposite face and concave face.The formation in gap does not need to utilize the spacer element of being made by non-magnetic material.

The embodiment of the assembly unshakable in one's determination that is used for the surface electronic element has also been described herein.Assembly unshakable in one's determination comprises an iron core, and it comprises and wholely be the monolithic body of magnetic material, and a plurality of conductor perforates are formed on the iron core, and space between each conductor perforate wherein, a plurality of gaps are integrally formed on the core construction and do not need to utilize interval insulant.Each gap and corresponding conductor perforate are communicated with, and body is not exclusively passed in each gap extension.

An embodiment of surface mounted component has been described herein.This element comprises single-core, and it comprises the whole body of being made by the magnetic material, and body has the longitudinal axis and transverse axis.A plurality of conductor perforates are formed on upward unshakable in one's determination and extend and are parallel to transverse axis, and the configuration of longitudinal axis space is prolonged in a plurality of conductor perforates.A plurality of non-magnetic gap physics are formed on the corresponding conductor perforate of adjacency on the core construction, and the formation of magnetic gap does not need to use insulating material to body.Conductor element is positioned at each conductor perforate, and gap contiguous conductor element, therefore is formed on and forms heterogeneous electronic component on the single-core.

Preferably, ferromagnetic element comprises two conductor perforates.In addition, core construction comprises six conductor perforates.Extend separately between a conductor perforate and a side in the gap.This element can be an inductor.

The embodiment of a magnetic cell has also been described.This element comprises that a monolithic core construction integral body is formed on body by the magnetic material, and it has non-circular shape, and body has relative side.The first conductor perforate is extended between the opposite flank fully, and whole to be positioned at the outer rim of side separately.The gap is integrally formed in not to be needed in the body to utilize the outer gap material to body, and the gap has first and second ends, and first end terminates in the first conductor tapping, and to its perforate, and second end extends to outer rim.Preferably, this element further comprises the second conductor perforate and second gap.

A kind of magnetic cell has also been described herein.This element comprises the single-core structure, and it is formed in the body by same magnetic material monolithic, and has the opposite flank.The first conductor perforate extends between the opposite flank also whole to be positioned at the outer rim of each side separately fully.First gap is integrally formed in the body and does not need to utilize the outer gap material in body, and the gap has first and second ends, and first end terminates in the first conductor perforate and to its perforate, second end extends to outer rim.C shape conductor element straight-line extension passes perforate, and conductor element has the opposite end, and the opposite end defines the mounted on surface end of element around edgewise bend.Preferably, element further comprises the second conductor perforate and second gap, and this element is an inductor.

Though described the present invention according to different specific embodiments, one skilled in the art will recognize that the present invention can improve in the purport and scope of claim.

Claims

1, a kind of magnetic cell comprises:

One single-core structure, it is formed substantially by the magnetic material and is the body of rectangle, and described body is limited by opposing end faces, and relative side extends between end face, and end face and bottom surface and side and end face interconnection;

With the first conductor perforate at interval of each end face, end face and bottom surface, the described first conductor perforate is extended integral body and is passed body;

Be integrally formed in the body and extend transverse to first gap of conductor perforate, described gap is extended and is not exclusively passed body; And

Pass first conductor element that conductive channel is set up in the first conductor perforate, described first conductor element is configured to the mounted on surface end.

2, magnetic cell according to claim 1, wherein conductor element comprises rectangular conductor.

3, magnetic cell as claimed in claim 1 further comprises: the second conductor perforate, its be formed on the body and and the first conductor perforate separately; Second gap, it is formed on body and extends transverse to the second conductor perforate; Reach second conductor element of setting up conductive channel by the second conductor perforate.

4, magnetic cell according to claim 1, wherein first gap extends to the first conductor perforate.

5, magnetic cell as claimed in claim 1, wherein first gap and the first conductor perforate are arranged to the configuration of T shape.

6, magnetic cell as claimed in claim 1, wherein said body is limited by the longitudinal axis and transverse axis, and the first conductor perforate and first gap are basically parallel to transverse axis extends, the basic vertical extent mutually in the first conductor perforate and first gap.

7, magnetic cell as claimed in claim 1, wherein the bottom surface comprises relative concave face, first conductor element is around opposite face and concave face bending.

8, magnetic cell as claimed in claim 1, wherein conductor element in shape with the perforate complementation.

9, magnetic cell as claimed in claim 1, the formation of its intermediate gap do not need to utilize the spacer element of being made by non-magnetic material.

10, a kind of assembly unshakable in one's determination that is used for the surface electronic element, this iron core assembly comprises:

An iron core, it comprises whole first body of being made by the magnetic material, a plurality of conductor perforates are formed in the iron core, space between wherein a plurality of conductor perforates, and a plurality of gaps do not need to utilize the insulation gap material monolithic to be formed in the core construction, wherein each gap and corresponding conductor perforate are communicated with, and not exclusively extend in body in each gap.

11, assembly unshakable in one's determination as claimed in claim 10 further is included in the conductor element in the corresponding conductor perforate.

12, assembly unshakable in one's determination as claimed in claim 10, wherein each gap is basically perpendicular to corresponding conductor perforate extension.

13, assembly unshakable in one's determination as claimed in claim 10, wherein the conductor perforate is rectangle substantially.

14, assembly unshakable in one's determination as claimed in claim 10, wherein each gap and corresponding conductor perforate connection.

15, assembly unshakable in one's determination as claimed in claim 10, wherein the gap of conductor perforate and its connection is arranged to T shape structure.

16, assembly unshakable in one's determination as claimed in claim 10, its intermediate gap extends transverse to the conductor perforate.

17, a kind of surface mounted electronic elements comprises:

Single-core, it comprises the whole body of being made by the magnetic material, described body has the longitudinal axis and transverse axis;

Be formed in the iron core and be parallel to a plurality of conductor perforates that transverse axis extends, described a plurality of conductor perforates are along longitudinal axis space;

Physics is formed on a plurality of non-magnetic interval of the conductor perforate of adjacency correspondence in the core construction, and described magnetic forms does not at interval need to utilize insulating material to be applied to body; And

Be arranged in the conductor element of each conductor perforate, therefore described gap forms heterogeneous electronic component in abutting connection with described conductor element in single-core.

18, electronic component as claimed in claim 17, wherein core construction comprises two conductor perforates.

19, electronic component as claimed in claim 17, wherein core construction comprises six conductor perforates.

20, electronic component as claimed in claim 17, wherein air gap extends transverse to corresponding conductor perforate.

21, electronic component as claimed in claim 17, wherein each gap is connected with a described conductor perforate.

22, electronic component as claimed in claim 17, wherein the conductor perforate is rectangle substantially.

23, electronic component as claimed in claim 17, its intermediate gap and conductor perforate are arranged to T shape structure.

24, electronic component as claimed in claim 17, wherein body is rectangle substantially.

25, electronic component as claimed in claim 17, its intermediate gap extend between a described conductor perforate and a described side separately.

26, electronic component as claimed in claim 17, wherein this element is an inductor.

27, a kind of magnetic cell comprises:

The monolithic core construction, its integral body is made body and is had non-circular shape by the magnetic material, and described body has the opposite flank;

The first conductor perforate, extend fully between the opposite flank and be positioned at it and the outer rim of each side separately; And

A gap is integrally formed in the body and does not need to utilize the outer gap material to body, and described gap has first and second ends, and described first end terminates in the first conductor perforate and opens to it, and described second end extends to outer rim.

28, magnetic cell as claimed in claim 27 further comprises the second conductor perforate and second gap.

29, magnetic cell as claimed in claim 27 comprises further that rectangular conductor passes that the first conductor perforate is inserted and around edgewise bend.

30, a kind of magnetic cell comprises:

A single-core structure, integral body is made body and is had relative side by single magnetic material;

The first conductor perforate, integral body extends between the opposite flank, and internally be positioned at the outer rim of each side separately;

First gap is integrally formed on the body and does not need to utilize the outer gap material to body, and the gap has first and second ends, and described first end ends at the first conductor perforate and open to it, and described second end extends to outer rim; And

Linear extension passes the C shape conductor element of perforate, and described conductor element has the opposite end, reels around the side and define the mounted on surface end of element in described opposite end.

31,, further comprise the second conductor perforate and second gap as the magnetic cell of claim 30.

32, as the magnetic cell of right 30, wherein this element is an inductor.